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Surface Miner

The document discusses the techno-economic feasibility analysis of using a surface miner versus a shovel for coal mining. It provides background on the conventional shovel-dumper mining method and explains the advantages of using a surface miner such as continuous cutting, direct loading, and no need for blasting or primary crushing. The document then covers various surface mining methods using a surface miner, applicability, advantages like the windrow method, surface miners currently in use, sustainability benefits, and a case study cost-benefit analysis showing surface miners have lower cost per metric ton compared to using a shovel. It concludes that surface miners provide the highest quality coal with less waste dilution and flexibility in operation.

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728 views

Surface Miner

The document discusses the techno-economic feasibility analysis of using a surface miner versus a shovel for coal mining. It provides background on the conventional shovel-dumper mining method and explains the advantages of using a surface miner such as continuous cutting, direct loading, and no need for blasting or primary crushing. The document then covers various surface mining methods using a surface miner, applicability, advantages like the windrow method, surface miners currently in use, sustainability benefits, and a case study cost-benefit analysis showing surface miners have lower cost per metric ton compared to using a shovel. It concludes that surface miners provide the highest quality coal with less waste dilution and flexibility in operation.

Uploaded by

silver_grains_kkp
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 15

TECHNO-ECONOMIC FEASIBILITY ANALYSIS OF SURFACE MINER Vs SHOVEL IN COAL MINING

Krishna Kant
Indian Institute of Management Calcutta
1

Agenda
Mining with shovel-dumper combination Why surface miner ? Working principle and various mining methods using surface miner Applicability and Favoring Issues Advantage with Windrow method Surface Miners in use Sustainability with Surface Miner Cost benefit analysis- a case study Conclusion

Mining with Shovel Dumper combination

DRILLING

BLASTING

Shovel
EXCAVATION

HAULAGE

UNLOADING AT CRUSHING PLANT


3

Why Surface Miner?


Clean, level & stable surface Continuous cutting

Direct loading

Crushed aggregate

Precise cutting depth

Drilling

Blasting

Loading

Crushing

Continuous Surface Miner


The conventional method of mining includes
Drilling, Blasting and Face loading. These Mining operations frequently involve a high degree of environmental disturbance in terms of fly rock, ground & air vibration, dust and noise.
Cost of mining and quality control are the main issues . To overcome the above problems and to minimize the adverse impacts of mining it is desirable to adopt an eco-friendly mining technology.
4

Working Principle of Surface Miner


The surface miner is crawler-mounted machine having a cutting drum located b/w two sets of crawlers and positioned at the center of the machine.

The drum is lowered and raised by hydraulic system with powerful hydraulic motors thereby varying the depth of cut
The material cut is loaded onto the primary and secondary discharge conveyors for loading the same on to the loading / transporting equipment. The rear crawler travel at lower level then the front crawlers to adjust to the required depth

Turn Back Method

Various mining methods using Surface Miner

INDIRECT LOADING (WINDROW)

DIRECT TRUCK LOADING

SIDE CASTING
6

Applicability
Flat or gently inclined deposit. Best suited for rock compressive strength up to 60 MPa. Less abrasive rock. Non sticky material Thin seams or thin dirt bands Sized material production Environmentally sensitive areas where blasting is prohibited or restricted.

In general surface miners are capable of cutting rocks of hardness b/w 10-80 MPa. Under certain circumstances (E.g. Highly fractured material) even harder material can be cut economically.

Favoring Issues
Mining coal with a high production and performance rate without using blasting Environment: Without abnormal sound, ground vibration and dust

Selective mining: Improving coal quality, capable of thin seam extraction


Sized product: Eliminates primary crushing of mineral completely Reduces the time, effective carrying capacity of haulage equipment fetching more money and minimizes damage to trucks deployed for loading Manpower: Needs less workforce as compared to traditional mining with shovel as excavator Safety: Safe in Naxalite effective areas as no explosive is required. Also, Hard surface less chances of fire and slope instability High available time utilization: No drilling and blasting related wastage of

time.(from approx. 5,000 to 6,000 operating hours per year)


Overall mining cost :Reduces due to no drilling, blasting and primary crushing.

Advantage with Windrow method


Even and solid surface which was initially produced by the Surface Miners allows effective loading operations for the front-end loaders and the fast and safe operation of the additional trucks. It guarantees a higher productivity rate for the Surface Miners since there are no waiting times for the trucks involved. The cut material which has been laid down in advance can be used as a mine stockpile (emergency buffer). Loading can be done on demand.

Surface Miners in use


L&T: KSM223, KSM 303,KSM304 Wirtgen: 2200 SM, 2500 SM, 4200 SM

Today, more than 120 Surface Miners are used for coal and limestone mining in India Used in Singereni Collieries Company Limited,Mahanadi Coal Fields ,South-Eastern Coal Fields and Central Coal Fields of Coal India Ltd.
9

Sustainability with Surface Miner


We are competing for finite resources in a world that is increasingly focused
on sustainability, so we have to invest in a manner that not only strengthens our competitiveness but also produces maximum benefit for local communities.

Ingredients of sustainability with Surface Miner :


Environment friendly- better Air quality ,less Noise and vibration Optimum use of resources in a scientific /systematic manner to extract maximum resources in the most economical scale Safety -A safe working environment where the employees can meet production objectives without risk of injury

10

Cost benefit analysis-Mandakini Coal Mine


Assumptions/data taken: 7.5 Million per annum coal excavation Various figures taken are from practical experience/equipment manufacturers Coal is moderately hard( Compressive strength~14MPa.) Figures may vary for different mining conditions and output required

40 35 30 25 20 15 10 5 0
Shovel SM(Windrow) SM(Direct)

Loader Cost Crushing Cost


Blasting Cost

Rs per MT

Drilling Cost Shovel/SM Cost

Calculations Remark: Cost incurred due to dilution of coal with waste has not been included
11

Conclusion
Electric Powered machines are more cost effective but flexibility is lost. ROM coal with high quality will be produced due to less dilution from waste by application of Surface Miner.

Surface Miner with Direct Loading gives maximum cost benefits but it requires high level of supervision and control.
The Surface Miner with Loader combination gives the highest selectivity and flexibility in operation involving changing mining conditions . Combination of Direct Loading by Surface Miner and Surface Miner-Loader combination methods gives best results. Use of Surface Miner gives other benefits over Shovel like mineral conservation, it is more environment friendly and safe. It is recommended method in blasting restricted and Naxalite affected areas Suitable machines/equipment have to be selected by studying parameters such as ease of rock excavation, ability of high selective excavation, rate of production and productivity demands, capital and operational cost and mine features
12

References
http://www.wirtgenindia.com/ http://www.larsentoubro.com/ http://www.google.com Dey, K (1999), Performance Analysis of Continuous Surface Miner in Indian surface Coal Mines-a case study, M-Tech Thesis, Department of Mining Engg. Indian School of Mines University, Dhanbad. Sen, P. and Dey, K.(2000), Continuous surface Miner in Indian Surface Coal Mining, A case study, surface Mining (BrounKohle & others),52(2000),No.4 July-August,pp371-376

13

14

S.No.

Cost in Rupees/MT

SHOVEL

SURFACE MINER (WINDROW) 14.30 14.92

SURFACE MINER (DIRECT LOADING) 24.33 -

1 2 3 4 6

Total Owning & Operating Cost per MT Drilling -Total Owning & Operating Cost per MT Blasting Cost per MT Primary Crushing-Total Owning & Operating Cost per MT Loader for loading in dumper -Total Owning & Operating Cost per MT OVERALL COST PER MT WITH LOADER

12.42 2.57 18.13 4.56 -

37.69

29.22

24.33

15

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